High pressure cable head connector

ABSTRACT

The present invention relates to a sealing cable connector device for high-pressure applications including a first connector part (1) and a second connector part (5) including an axial channel for allowing a cable (6) to extend, the first connector part having a cylindrical channel with a radially oriented inner surface (1a) and the second connector part being adapted to be introduced into said channel and having a corresponding shape in the radial direction, said second connector part having a radially oriented front end surface (4a), the first and second connector parts including locking means being adapted to applying an axial force and lock the parts together after connecting. At least one spring bevel ring (2) is positioned at the inner surface in said cavity having radial dimensions corresponding to radial dimensions of the cavity between the cable and outer walls of the cavity.

The present invention relates to a high-pressure cable head connector, e.g. for connecting downhole cable with gauge for use in downhole completion.

A cable head is part of the downhole gauge tool used for connecting a downhole cable to a gauge and need to ensure and protect connection of the downhole cable with the gauge with a double barrier metal to metal seals.

Known solutions for high pressure environments have included complicated structures with a number of sealing rings. One example of the prior art is presented in FIG. 1 where two rings 01 are forced in the radial direction when the connector parts 02,03 are pushed in the longitudinal direction. This solution requires that the surface of the cable is smooth in order to give the sealing rings 01 sufficient contact with the cable surface, and the number of parts needed for providing two pressure barriers increases the risk of failure. Examples showing such solutions are well known within the field and may be found in GB2287997, U.S. Pat. Nos. 5,823,256, 3,445,128 and 3,325,192. A slightly different solution is presented in U.S. Pat. No. 3,985,379 where a frustoconical ring is used to increase the force on part of the sleeve toward the pipe, this increasing the friction, but still the limitations discussed above apply as the force is distributed to avoid deforming the pipe material.

It is an object of the present invention to provide a relatively inexpensive connector with high pressure integrity, which is easily assembled in offshore applications while reducing the required qualification of the users. More specifically the objective problem may be defined as to create a connection seal with a high pressure integrity both outside against housing and inside against metal pipe or cable. The objective problem to be solved according to the preferred embodiment of the invention is how to create a double metal connection seal, outside against housing and inside against a pipe or cable with a hard, usually metal, surface. Note that “cable” in the present specification should also be interpreted as “pipe” under comparable situations

The present invention relates generally to metal to metal seal and particularly to a resilient metal bevel seal embedded between a cable head housing and a ¼″ downhole tubing encapsulated cable (TEC). More specifically the present invention is characterized as presented in the accompanying claims.

This provides a seal interface for sealing against outside pressure and in the same time for inside pressure of the well fluid in conditions of high pressure and high temperature. This is provided by forcing the sealing ring both outward into the connector housing and inward to the cable surface, the cable surface being made from a metal or another material having similar characteristics. In a preferred embodiment two rings are used for redundancy.

The present invention utilizes ring shaped bevel springs that are compressed to a predetermined deflection, generating a sealing stress by the resilient bevel spring seal shape. This way a compact connector is provided using less parts and thus minimizing the risk of failure, and that is easy to assemble, thus reducing the time to rig a system. The components may be used as is without contact preparations of the cable.

The barriers provided by the present invention are thus obtained by radial deformation and elastic stress in the contact area. direct on the sealing elements, without any intermediate part.

It is essential for the present invention is to achieve two barriers of the same level and in the same time, both sealing against HPHT (high pressure, high temperature) fluid, outside against the housing and inside against the pipe from tubing encased cable (TEC).

In addition:

-   -   Seals are deformed in control manner and all the time in the         same fixed and locked position.     -   The two sealing barriers testable independent in the flow         direction.     -   Both barriers are equals in terms of capability of sealing         against fluid with high pressure and high temperature     -   Both barriers have a controlled deformation to achieve the same         contact stress.     -   Both seals have capability to seal HPHT in both direction, from         right to left and vice versa.

The invention will be described more in detail with reference to the accompanying drawings, illustrating the invention by way of examples.

FIG. 1 illustrates the prior art.

FIG. 2 illustrates a longitudinal cross section of the preferred embodiment of the invention.

FIG. 3 illustrates the sealing mechanism of the invention.

FIG. 4 illustrates a simplified embodiment of the invention.

FIG. 5 illustrates an alternative embodiment of the invention.

As is illustrated in FIG. 2 the sealed connector according to the invention includes a first connector part 1 and a second connector part 5 adapted to be locked or screwed together applying an axial force towards each other. A cable or pipe 6, preferably a TEC or other cables with a hard, outer surface, extends through the connector.

As can be seen from the drawing two bevel rings 2 are positioned between the first and second parts in the axial direction. The front end of the second connector part 5 and the inner surface of the first connector part have radially plane section and the bevel rings 2 have a frustoconical shape defining an angle relative to the radial and axial directions. In FIG. 2 the bevel rings are tilted in opposite directions toward each other with a stopper ring 3 between them. The stopper ring limiting how much the shape of the bevel ring can change then the connector parts are pressed together, limiting the force toward, and deformation of, the outer part of the cable. Preferably the front end of the second connector part 4 includes a low friction element surface 4 a to be able to rotate relative to the bevel ring if screwed into the connector.

FIG. 3 illustrates the function of the bevel rings 2. The bevel ring cross section is shown as a rounded essentially rectangular shape in two situations, the uncompressed position 7 and the compressed position 8. Before the compression the bevel ring 2 in the illustrated example 7 has an angle of 45° relative to the longitudinal axis corresponding to both the inner house surface of the first connector part 1 and the outer surface of the cable 6. After being subject to a longitudinal force toward the inner wall 1 a of the first connector part by the front end 4 of the second connector part 5 the bevel ring is tilted, e.g. by 5° as illustrated in the compressed position 8, in which case the outer edge 2 c of the bevel ring is forced in the radial direction into the inner surface of the first connector part 1 and the inner edge 2 d toward the outer surface of the cable 6. This forces a close connection between the surfaces and the bevel ring and thus sealing the connection between the first connector part and the cable.

Thus, when the axial pressure is applied the bevel seals 2 are embedded into a housing 1 and compressed against a cable head housing 6 shoulder, preferably by a metallic threaded locker part until the flat surface of the bevel seals are mating with flat surface from cable head housing respective to the flat surface of the locker part.

As can be seen from the cross section of the bevel ring in FIG. 3 the rounded rectangular shape is preferably about 2:1 ratio between radial dimension and thickness, and may include a cut off edge 2 a toward the front end of the second connector part, having an angle, e.g. 25° in the case when the bevel ring is tilted by 45°, from the bevel seal surface. This is to receive the front end 4 of the second connector (not shown in FIG. 3), and, when a tilt of 5° has been applied the cutoff edge 2 a is perpendicular to the longitudinal direction and thus parallel to the front end 4 of the second connector part 5. This will stop the tilting at 5 degrees, before amplitude point of rotation, thus protecting the cable 6 and housing 1. A similar cutoff edge may also be provided on the edge 2 b interacting with the inner surface 1 a of the first connector part. This will create a controlled contact stress to avoid the TEC to be deformed on the inner wall against cable.

The stopper 3 illustrated in FIG. 2 may have the same function in providing a bed stopping for the tilt at a certain angle where the sealing is obtained without applying more stress or deforming the bevel seal, cable or housing more than an allowed degree.

Bevel seals will have an axial movement and in the same time a rotation with 20 degrees, stopping rotation with 5 degrees before amplitude of the movement between the bevel seal and housing and respective downhole cable. This way a spring back force is obtained as well as protection of the parts.

During the movement and after, a spring back force will exert uniform pressure on the sealing interface and keeps a preset load on the seal with an equal distribution outside to the housing and inside to the cable pipe. Compressed bevel seal system is capable to provide a pressure integrity mechanism which form a pressure seal on a tubular wall both outside and inside. A locking mechanism may be used to avoid relaxing the bevel seals by unscrewing locking part.

FIGS. 4 and 5 illustrates alternative embodiments where FIG. 4 only includes one bevel seal 2, compressed between the front surface 4 of the second connector part and the inner surface 1 a of the first connector part 1. In FIG. 5 a similar solution is shown where two bevel rings are used, providing a redundancy in the sealing. In these figures the rectangular cross sections show cutoffs on both sides of the bevel rings, both on the inner surface 1 a and the front surface 4.

The present invention thus relates to a high pressure cable head connector, e.g. for connecting downhole cable to a measurement device, e.g. a pressure sensor, for use in downhole completion. The sealing cable connection device is made for high pressure applications including a first connector part and a second connector part including an axial channel for allowing a cable or pipe to extend, where the cable preferably has an outer surface made of metal or another hard material that can be deformed when subject to a force. The first connector part 1 having a cylindrical channel with a radially oriented inner surface 1 a and the second connector part 5 being adapted to be introduced into said channel and having a corresponding shape in the radial direction, said second connector part having a radially oriented front end surface 4 a. The cavity being coaxially oriented around the cable channel 6. The first and second connector parts include locking means being adapted to applying an axial force and lock the parts together after connecting.

The inner volume of said receiving cavity includes at least one bevel ring 2 having radial dimensions corresponding to the radial dimensions of the cavity between the cable and the outer walls of the cavity, the bevel rings preferably having an essentially frustoconical shape in the longitudinal direction. At the application of said axial force the outer parts of said bevel rings are forced into said cavity wall as well as into a cable or pipe in said cable channel, thus deforming the material in the cavity wall and cable. Preferably the cavity walls and bevel ring(s) are made from a metal and the cable or pipe is a tubing encapsuled cable with a hard or metal outer surface. Preferably the material for tubing encapsulate cable is nickel alloy 625 or nickel alloy 825 and the bevel seal rings are made from nickel alloy 718. Other bevel ring shapes may also be contemplated as long as they provide a force in the radial direction when subject to an axial force

The first and second connector parts may be threaded so that the axial force is applied by screwing the parts together. and/or may be provided with other locking mechanisms.

Preferably the bevel rings are constituted by springs exerting high contact stress equal for contact between said outer wall of said cavity and the ring and outer surface of the cable. The bevel rings may be adapted to, when compressed, act like an energized spring who exerts high contact stress equal to compensate thermal expansion of the parts.

The present invention thus provides a first seal barrier for sealing between a connector housing 1 and cable pipe 6 for protecting cable connection against well fluid. Preferably a second seal barrier is used to ensure redundancy of the primary seal. This is obtained using one or more bevel rings 2. Preferably two bevel rings are used being oriented back to back. Thus two bevel rings may provide a double bevel seal technology based on metal to metal sealing for HPHT (High Pressure, High Temperature) environment based on the shape of the seal, preferably being suitable for 25000 psi and 225 C. degrees.

As the bevel rings preferably have frustoconical shapes, the at least one bevel rings are rotated around cross intersection of the shape diagonals, as shown and discussed in relation to FIG. 3 in the controlled manner to ensure maximum contact stress against tubing encapsulate cable and in the same time against outer wall of the cavity when subject to an axial force. The bevel ring or rings are preferably stopped all the time in the same, predetermined position as provided by the cut off edge 2 a or by the limiter 3 in FIG. 2.

Using two bevel rings will have the advantage of providing two sealing barriers in the same time, preferably with the same leak proof capability of under HPHT (High Pressure High Temperature) conditions. 

1. A sealing cable connector device for high pressure applications, the sealing cable connector comprising a first connector part and a second connector part including an axial cable channel for allowing a cable to extend, the cable having a cross section comparable to the dimensions of the channel, the first connector part having a cylindrical connector channel with an outer wall having a larger cross section than the cable channel and with a radially oriented inner surface, and the second connector part being adapted to be introduced into the connector channel, the second connector part having a radially oriented front end surface, wherein a cavity is defined between the inner surface and the front end, the cavity being coaxially oriented around the cable channel, the first and second connector parts including locking means being adapted to applying an axial force and lock the parts together after connecting; wherein at least one spring bevel ring is positioned at the inner surface in the cavity having radial dimensions corresponding to the radial dimensions of the cavity between the cable channel and the radially outer walls of the connector channel, wherein the at least one spring bevel ring has a radial cross section having an essentially rectangular shape with rounded corners, and having a predetermined angle relative to the longitudinal axis of the cable; wherein at the application of the axial force between the first and second connector parts, the at least one spring bevel ring is tilted by the force between the inner surface and the end surface and thus forced in the radial direction both into the cavity wall and into the cable channel, so as to provide a sealing interaction both between the at least one spring bevel ring and the cavity wall and between the at least one spring bevel ring and the cable; and wherein the at least one spring bevel ring is adapted to, when compressed, to interact with the front end of at least one of the second connector and inner surface of the first connector part and thus act like an energized spring that exerts high contact stress into the cavity wall and into the cable channel to compensate thermal expansion of the parts.
 2. The cable connector device according to claim 1, wherein the cavity walls and bevel rings are made from a metal.
 3. The cable connector device according to claim 1, wherein the first and second parts are threaded, the axial force being applied by screwing the parts together.
 4. The cable connector device according to claim 1, including two spring bevel rings, the two spring bevel rings being positioned so as to have their radially outer parts extending from each other.
 5. The cable connector device according to claim 4, wherein the two spring bevel rings are constituted by springs exerting high contact stress equal for contact between the outer wall of the cavity and the spring bevel ring and outer surface of the cable.
 6. The cable connector device according to claim 1, wherein the inner surface, sat at least one spring bevel ring and the outer surface of the cable is made in metals.
 7. The cable connector device according to claim 6, wherein the material for tubing encapsulate cable is nickel alloy 625 or nickel alloy 825 and the bevel seal rings are made from nickel alloy
 718. 8. The cable connector device according to claim 1, wherein the at least one spring bevel ring has an essentially frustoconical shape.
 9. The cable connector device according with claim 8, wherein the at least one spring bevel ring is tilted in the controlled manner at the application of an axial force so as to ensure maximum contact stress against tubing encapsulate cable and in the same time against outer wall of the cavity.
 10. The cable connector device according with claim 9, wherein the at least one spring bevel ring is stopped at a predetermined position.
 11. The cable connector device according with claim 1, including two spring bevel rings providing two sealing barriers in the same time.
 12. The cable connector device according with claim 1, including two spring bevel rings providing 2 sealing barriers with the same leak proof capability in the HPHT conditions. 13-14. (canceled)
 15. The cable connector device according to claim 1, wherein the initial, angle of the spring bevel ring cross section in the uncompressed state is 45° relative to the longitudinal axis.
 16. The cable connector device according to claim 1, wherein the rectangular shape of the spring bevel ring has at least one cutoff edge at the corner adapted to interact with the front end of the second connector and/or inner surface of the first connector part, the angle of the cut off edge cutoff edge having an being chosen so as to be parallel to the front end when the spring bevel ring is compressed. 